Saw kerf calculator for metal cutting
A cutting list that ignores blade width can look feasible on paper and still run short on material. Kerf is the width of stock removed by the blade; it needs to be budgeted independently from finished part lengths.
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Finished parts + cutting allowances + leftover = stock length
What this calculation covers
MetalCut allows a kerf value in millimeters or inches. It typically assigns kerf for each saw cut, while recognizing when a final part exactly uses the remaining bar length and needs no separating cut. Head trim and tail reserve can also be specified.
The calculation is a stock-length planning model; it does not model tool deflection, thermal expansion, dimensional tolerances or cut quality.
A real-number cut list example
For three 900 mm pieces from one 3,000 mm bar, the finished parts total 2,700 mm. At three separate cuts of 3 mm each, kerf consumes 9 mm and the remaining stock is 291 mm. At 2 mm per cut, the remainder would be 294 mm.
Length balance: 2700 mm finished + 9 mm kerf + 291 mm leftover = 3000 mm stock.
This illustrative example assumes zero head trim and tail reserve. Always enter your actual machine allowances.
How to prepare a cutting plan
Measure your actual cut
Use the effective cut width for the actual blade and material; the nominal blade thickness may differ from the measured result.
Count only required separation cuts
A part that naturally matches the remaining stock may not need another separation cut.
Include other allowances
Head trim and tail reserve are separate from cut width and reduce available material.
Enter stock, parts and saw kerf in the free 1D MetalCut calculator.
Common questions
What does saw kerf mean?
It is the width of material lost to the cutting operation.
Is kerf always charged for every part?
Not in every layout. When the final part exactly matches the available remainder and no final separation is required, the planner can omit that last kerf.